Packaging unit

ABSTRACT

The invention pertains to a packaging unit for eggs or similar fragile articles, the packaging unit for instance being made of moulded pulp, and including a bottom part including compartments matching at least partially the outer contours of the articles contained within the unit, a cover part including a top surface and substantially planar front- and rear surfaces and substantially planar end surfaces, the cover part substantially having a rectangular shape with rounded corners, wherein the cover part includes denesting element near the end surfaces near the top surface of the cover part. The invention further pertains to such a packaging unit wherein the cover part at its corners includes portions reflecting the shape of the articles contained within the packaging unit, a portions being formed as a part taken out of a rounded corner and a part of the end surface of the cover part.

BACKGROUND

The present invention relates to a packaging unit for eggs and similar articles.

Egg cases or cartons are a well known example of such a packaging unit. An example of such an egg case is disclosed in U.S. Pat. No. 3,813,027 and EP-1,373,100. Usually, these egg cartons are made of moulded paper material or synthetic material, and comprise a number of pockets for accommodating eggs of similarly shaped, fragile articles like for instance kiwi fruits. These packaging units usually have a bottom part or tray section which has a number of pockets or compartments for holding the articles.

The packaging units further have a cover section or cover part which may be hingedly connected to the bottom part.

U.S. Pat. No. 3,50,083 discloses an egg carton with a bottom part and a cover part hingedly connected to it. The egg carton has denesting provisions formed from indentations. In order to function properly, the egg carton needs to come in two versions which need to be stacked alternately. Thus, stacking of two stacks may already lead to problems.

Production speed of packaging apparatus increases, with speeds up to 120.000 eggs per hour. Less human interference is desired and the packages need to be stacked in higher stacks. Therefore, machine handling of the packaging units needs to be improved.

The package units are provided to a packaging machine in a nested way, and need to be denested by the packaging machine. This needs to be done in a reliable way. Machine handling of these packaging units can therefore be improved.

Furthermore, regarding the strength, the stackability and denesting of the packaging units there is room for improvement.

SUMMARY OF THE INVENTION

The invention aims at providing an alternative packaging unit.

Another object of the invention is to improve the packaging unit.

Yet another object of the invention is to provide a packaging unit that can be handled by a machine in a more reliable way or faster.

The invention provides a packaging unit for eggs or similar fragile articles, said packaging unit for instance being made of moulded pulp, and comprising:

-   -   a bottom part comprising compartments matching at least         partially the outer contours of the articles contained within         said unit;     -   a cover part comprising a top surface and substantially planar         front- and rear surfaces and substantially planar end surfaces,         said cover part substantially having a rectangular shape with         rounded corners;

wherein said cover part comprises denesting means near the end surfaces near the top surface of the cover part.

This type of denesting means allows high-speed denesting. Furthermore, it does not need a modification which is visible from the outside of the packaging.

In an embodiment, said denesting means comprises an abutment surface below said top surface next to an end surface and is at least partially formed by a thickened part of the end surface or top surface. In this way, a denesting facility is created which requires only one version of the packaging. Furthermore, it is easy to create, in particular in moulded material. Finally, the denesting properties of such a facility are very solid.

In an embodiment, the denesting means comprises an abutment surface below the top surface next to an end surface.

In this way, an additional denesting provision can be provided which does not interfere with further functional features of the packaging. Furthermore, it prevents denesting problems of the cover part.

In a further embodiment, the abutment surface is at least partially formed by an indentation of said top surface near said end surface. The indentation can also rerve as a means for holding the packaging, for instance for transportation through a processing facility.

In yet a further embodiment, the abutment surface is at least partially formed by a thickened part of the end surface between said end surface and said indentation.

In another embodiment, the abutment surface comprises a thickened part of said front and/or rear surface and connecting to said top surface.

According to a further aspect, the invention provides a packaging unit for eggs or similar fragile articles, said packaging unit for instance being made of moulded pulp, and comprising:

-   -   a bottom part comprising compartments matching at least         partially the outer contours of the articles contained within         said unit;     -   a cover part comprising a top surface and substantially planar         front- and rear surfaces and substantially planar end surfaces,         said cover part substantially having a rectangular shape with         rounded corners;         wherein said cover part at its corners comprises portions         reflecting the shape of the articles contained within said         packaging unit, a portions being formed as a part taken out of a         rounded corner and a part of said end surface of said cover         part.

The portions provide a relatively strong shell portion protecting the articles. Furthermore, as part of the substantially planar end surface remains unaffected, it adds to the strength of the cover part and provides a possible location for a denesting provision, for instance. Furthermore it allows the provision of a large, rectangular labelling area on the cover part.

The portions reflecting the shape of the articles contained within a packaging unit are of a shape which gives for instance a consumer a direct association with for instance the egg contained within the packaging unit. This effect can be further intensified when the bottom part has compartments which are for instance egg-shaped and if the portions of the cover part visually seem to continue in a compartment of the bottom part.

The cover part of the invention can thus be thought of as a substantially rectangular box with a planar top surface, planar front and rear surfaces, and planar end surfaces. From the corners where these surfaces meet, a part of the wall can be thought of as having been pushed in and formed over the article inside, while leaving the rest/center part of the end surface unaffected. The remaining, substantially unaffected end surfaces between the portions thus extends beyond the portions.

Furthermore, the cover part can provide a large area for graphical and/or pictorial information. The cover part also provides room for denesting means.

In an embodiment, the portions form part of the corners of the cover part.

In an embodiment, a portions radially in a plane parallel to the top surface covers 80-110 degrees of an article, in particular a portions covers at least about 10-30% of the surface of an article. In that way, a part of the planar end surface can be left unaffected.

In an embodiment, between adjacent portions at an end of the cover part, part of the end surface of the cover part is not taken away or unaffected by said portions.

In an embodiment, between adjacent portions said top surface extends or continues beyond said portions and connects to the end surface between said portions. In fact, that extending or continuing part is in the plane or the rest of the top surface.

In an embodiment, at least one of said parts of said top surface between said adjacent portions is provided with a denesting means. In particular said extending part provides a good location for a denesting provision.

In an embodiment, symmetrically at both ends of said cover part near said top surface denesting means are provided.

In an embodiment, said denesting means comprises a denesting cam at the inner side of said cover part. When stacked, said cam rests against or abuts the top surface of an other, lower, nested packaging unit.

In an embodiment, said cover part comprises an indentation in said top surface, said lower part of said indentation forming an abutment surface for a denesting means. Said lower part can abut the top surface of an other, lower, nested packaging unit.

In an embodiment, said indentation has a wall at an inclined angle towards the end surface. This may strengthen the abutment surface.

In an embodiment, said denesting means comprise a filled part between the indentation and the end surface of said cover part. In that way, a well defined and ridged abutment surface is created.

In an embodiment, said top surface ends in a sharp border edge at the location near said portions. This provides additional strength and an interesting visual feature from a design point of view.

In an embodiment, said end surfaces bridge said adjacent portions.

In an embodiment, said portions are defined to have a positive curvature, and negative curvature parts connect said portions to said front- and rear surfaces, said top surface and said end surfaces, wherein said negative curvature parts continuously connect to said portions and at least in the upper region of the portions substantially discontinuously connect to said top surface and said front surface and rear surface for providing a sharp corner at the connection of said front and rear surfaces and said top surface. Again, this can provide additional strength and at the same time a pleasant visual aspect.

The invention further relates to a packaging unit for eggs or similar fragile articles, said packaging unit for instance being made of moulded pulp, and comprising:

-   -   a bottom part comprising at least one outwardly protruding cam;     -   a cover part comprising a substantially planar top surface and a         substantially planar side surface at the position of the cam,         which extends beyond said cam and which is provided with an         opening matching the circumferential shape of said cam, said cam         protruding through said opening when said cover part closes off         said bottom part;

wherein said opening is bounded by a wall part, extending from near said top surface to said cam and forming a recessed part of said side surface

In previous packagings, like for instance egg cases, the opening for the cam was merely a through hole in a wall of the packaging. The current shape of the opening of this aspect of the invention, which may be the subject of a divisional application, provides a clear indication of the cam and makes the cam visible when the top surface of the packaging is examined This becomes even more important when the closure of the packaging is improved to provide a better machine handling, for instance. This is for instance the case when the cam has an receiving space and the opening has a lip which reaches into this receiving space when the packaging is closes. The lower side of the lip can for instance be open for receiving this lip. The new opening directs the finger of a used directly in the right direction for pushing the lip towards the inside of the packaging. Additionally, the wall part provides an extra stiffening of the cover part. The wall part thus forms a sort of niche or alcove in the side wall at the location of the opening for the cam. In an embodiment, the recess is formed in a way to be visible when looking down at the packaging on the top surface. In that way, a person wanting to open the packaging can easily see this provision.

In an embodiment said wall part is being inwardly angled with respect to said side surface. In another embodiment, the wall part is inwardly staggered with respect to the surface of the side wall. In either one of these embodiments, the wall part can run all the way up to the top surface and take a part or slice away from the top wall.

The invention further relates to a packaging unit comprising one or more of the characterising features described in the description and/or shown in the attached drawings, and to a method comprising one or more of the characterising features described in the description and/or shown in the attached drawings.

The various aspects discussed in this patent can be combined in order to provide additional advantageous advantages. Furthermore, several of the aspects discussed and disclosed in this descriptions or shown in the drawings can be the topic of one or more divisional applications.

DESCRIPTION OF THE DRAWINGS

The invention will be further elucidated referring to an embodiment of a packaging unit shown in the drawings wherein shown in:

FIG. 1 a perspective view of two packaging units interconnected at one of their end surfaces;

FIG. 2 FIG. 1 with the cover parts of the packaging units in cross section;

FIG. 3 nested packaging units in the view of FIG. 2;

FIG. 4 the nested packaging units of FIG. 3 in a denesting apparatus;

FIG. 5 a detail of FIG. 4 in cross section;

FIG. 6 a detail of an alternative closure of a packaging unit;

FIG. 7 a cross section through FIG. 6.

DETAILED DESCRIPTION OF EMBODIMENTS

In FIG. 1, a perspective view is shown of two packaging units 1, 1′ which are interconnected at their end surface sides. The two packaging units are here connected via bridging parts 15 and 16 at their ends. Both packaging units 1, 1′ can accommodate 6 eggs. Before or more preferred, after eggs or other articles have been placed in the compartments, and possibly after the packaging units have been closed, the bridging parts 15, 16 between both packaging units 1, 1′ can be deleted, for instance by cutting. Now first one packaging units 1 will be described in detail.

Packaging unit 1 has a bottom part 2 and a cover part 3. Cover part 3 is here (not visible) hingedly connected to the bottom part 2. The bottom part 2 has compartments 4 for accommodating the fragile articles, in order to maintain them in an upright position and preventing them from touching one another. These compartments 4 are well known in the art.

In order to lock the cover part 3 on bottom part 2, in this embodiment the bottom part 2 has a locking flap 5 hingedly connected to it, along its longitudinal or front side. This locking flap 5 is provided with a cam 6 which matching an opening 10 in the front surface 8 of the cover part 3. The locking provision of locking flap 5 with the cam 6 and the opening 10 in the cover part 3 as such is well known in the art. Cam 6 substantially fits closely in opening 10.

The cover part 3 of this embodiment further has a planar top surface 7, a planar front surface 8 and a planar rear surface (not visible here). These surfaces together provide here a rectangular area onto which a label can be provided. A rectangular label is advantageous from a handling point of view. Furthermore, proper application of a substantially rectangular label is easier and more reliable.

The cover part 3 in this embodiment further has substantially planar end surfaces 9 and 9′. These end surfaces 9, 9′ and front surface 8 and the rear surface (not visible here) are connected via portions 12, 12′, 12″ and 12′″ reflecting the shape of the articles contained within said packaging unit. In fact, the lower rim or peripheral flange 11, 11′ shows the lower side of the cover part 3 which shows a shape having end surfaces which connect to the front and rear surfaces via rounded corners. From these virtual, rounded, cylindrical corners, parts have been taken out, or, so to say, the wall has been reformed towards the inside of the cover part 3, so as to result in the portions 12, 12′, 12″, 12′″. At their lower ends, these portions almost follow the original rounded, cylindrical corners. Higher up, larger parts have been taken out. Thus, the width of the end portions 9, 9′ becomes smaller closer to the top surface 7. The portions 12, 12′, 12″, 12′″ are defined as having a positive curvature. The portions connect to various surfaces via negatively curved parts. These negative curved parts continuously connect to the portions, but substantially discontinuously connect to the surfaces. This results in the relatively sharp edges 21, 21′, 21″, 21′″. This not only results in a design with an aesthetically exiting aspect, but also defines an almost rectangular area for labelling.

In the sideward protruding parts of the top surface 7 which continue into the end surfaces 9. 9′, indentations 13, 13′ have been provided. These indentations 13, 13′ have the visual effect of emphasizing the rectangular area provided by the top surface 7, the front surface 8, and the (hidden) rear surface. Furthermore, it increase the strength of the cover part 3 and provides a denesting means without interfering with the labelling area.

Here, the indentations 13, 13′ have sloping walls 14, 14′. These walls 14, 14′ are inclined towards the end surfaces 9, 9′, respectively.

In FIG. 2 which shows the cover parts in cross section the construction of the denesting means 13, 13′ of this embodiment an be seem in detail. The space 17 between the indentations 13, 13′ and the end surfaces 9, 9′ are completely filled, thus together with the bottom part of the indentations 13, 13′ forming abutment surfaces 18, 18′. Together with the rims 19, 19′ which in the stacked situation of FIG. 3 abut abutment surfaces 18, 18′ and thus provides a distance between the top surfaces of packaging units 1 and 1″, this makes de-stacking or de-nesting of the packaging units 1, 1′ with respect to units 1″ and 1′ easier and more reliable. This becomes more and more important as the packaging speed of the packaging apparatus increases.

FIG. 4 shows the packaging units of FIG. 3 in a denesting part of an embodiment of a packaging apparatus. To that end, the packaging apparatus has a support 40, 40′ for supporting the lowest packaging units and has denesting parts 41, 41′ for engaging top packaging units 1, 1′.

FIG. 5 shows these parts in more detail and in cross section. The denesting part 41 has a cam 42 which engages the lower rim 20′ of cover part 7″. The packaging apparatus further has an engaging part 43 which has an gripping end 44 which holds the lower packaging unit 1″ against support 40. As the abutment surface 18′ rests on rim 19″ and keeps the cover parts of both packaging units at a distance, the makes it easier to engage only one packaging unit, and prevents two units to stick together.

In FIG. 6, another aspect of the new egg case is shown. Here, the opening 10 in front wall 8 has a lip 50. This lip reaches in a recess in the lower side of cam 6 (not visible in this drawing). The opening 10 at its upper side has a wall part 51 which here runs from the proximity of the top surface up to the upper side of cam 6, locally forming a recess in the surface of front wall 8.

In FIG. 7, the locking flap 5 is provided with cam 6. In this embodiment, the lower side of cam 6 is open, and lip 50 extends inside cam 6. Wall part 51 here runs from the top surface 7 of the top wall up to the upper side of the cam 6 and abuts the cam 6. It also takes away part of the top wall. The wall part 51 here has a rounded shape, like part of a cylinder wall.

The packaging unit can also have any number of compartments and any number of rows of compartments and any number of compartments per row. When the packaging unit has for instance three rows, the end surface 9, 9′ may in an embodiment extend between portions provided at each corner, i.e. four portions per packaging unit. In another embodiment, there may be a portion reflecting the shape of an article for each row. The middle row thus would have a portion reflecting the shape of for instance an egg, and this portion would more or less smoothly at both sides continue into two end surfaces.

It will also be obvious that the above description and drawings are included to illustrate some embodiments of the invention, and not to limit the scope of protection. Starting from this disclosure, many more embodiments will be evident to a skilled person which are within the scope of protection and the essence of this invention and which are obvious combinations of prior art techniques and the disclosure of this patent. 

1-21. (canceled)
 22. Packaging unit for eggs or similar fragile articles, said packaging unit for instance being made of moulded pulp, and comprising: a bottom part comprising compartments matching at least partially the outer contours of the articles contained within said unit; a cover part comprising a top surface and substantially planar front- and rear surfaces and substantially planar end surfaces, said cover part substantially having a rectangular shape with rounded corners; wherein said cover part comprises denesting means near the end surfaces near the top surface of the cover part, said denesting means comprises an abutment surface below said top surface next to an end surface and is at least partially formed by a thickened part of the end surface or top surface.
 23. Packaging unit according to claim 22, wherein said abutment surface is at least partially formed by an indentation of said top surface near said end surface.
 24. Packaging unit according to claim 22, wherein said abutment surface is at least partially formed by a thickened part of the end surface between said end surface and said indentation.
 25. Packaging unit according to claim 22, wherein said abutment surface comprises a thickened part of said front and/or rear surface and connecting to said top surface.
 26. Packaging unit for eggs or similar fragile articles, said packaging unit for instance being made of moulded pulp, and comprising: a bottom part comprising compartments matching at least partially the outer contours of the articles contained within said unit; a cover part comprising a top surface and substantially planar front- and rear surfaces and substantially planar end surfaces, said cover part substantially having a rectangular shape with rounded corners; wherein said cover part comprises denesting means near the end surfaces near the top surface of the cover part wherein said denesting means comprises an abutment surface below the top surface next to an end surface wherein said abutment surface comprises a thickened part of said front and/or rear surface and connecting to said top surface.
 27. Packaging unit according to claim 23, wherein said abutment surface is at least partially formed by a thickened part of the end surface between said end surface and said indentation. 